ML031540545

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Code Relief, Relief from Volumetric Examination Requirements on Regenerative Heat Exchangers
ML031540545
Person / Time
Site: Catawba  Duke Energy icon.png
Issue date: 05/22/2003
From: Gordon Peterson
Duke Energy Corp, Duke Power Co
To:
Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML031540545 (11)
v • d • e


Text

PW Duke GARY R.

PETERSON OrPower.

Vice President A Duke Energy Company Catawba Nuclear Station Duke Power CNO1 VP / 4800 Concord Rd.

York, SC 29745 803 831 4251 803 831 3221 fax grpeters@duke-energy.com May 22, 2003 U.S. Nuclear Regulatory Commission Attention:

Document Control Desk Washington, D.C. 20555

Subject:

Duke Energy Corporation Catawba Nuclear Station, Units 1 and 2 Docket Numbers 50-413 and 50-414 Request for Relief Number 03-001 Relief from Volumetric Examination Requirements on Regenerative Heat Exchangers Pursuant to 10 CFR 50.55a(a)(3)(ii), please find attached Request for Relief 03-001.

This request seeks relief from Section XI requirements of the ASME Boiler and Pressure Vessel Code, 1989 Edition with no Addenda.

Specifically, this request seeks relief from performing volumetric examinations on the Unit 1 and Unit 2 Regenerative Heat Exchangers as required by Table IWC-2500-1, Examination Category C-A, Pressure Retaining Welds in Pressure Vessels, because compliance with the specified requirements would result in hardship or unusual difficulty without a compensating increase in the level of quality and safety.

Catawba is requesting NRC review and approval of this request at your earliest convenience.

The NRC has previously reviewed and approved a similar request for McGuire Nuclear Station, Units 1 and 2 on December 2, 1999 (TAC Numbers MA3756 and MA3757).

The attachment to this letter contains all technical information necessary in support of this request for relief.

There are no regulatory commitments contained in this letter or its attachment.

If you have any questions concerning this material, please call L.J. Rudy at (803) 831-3084.

AO.l41 www. duke-energy. com

Document Control Desk Page 2 May 22, 2003 Ve%lYpr s

Gary R. Peterson LJR/s Attachment xc (with attachment):

L.A. Reyes, Regional Administrator U.S. Nuclear Regulatory Commission, Region II Atlanta Federal Center 61 Forsyth St., SW, Suite 23T85 Atlanta, GA 30303 E.F. Guthrie, Senior Resident Inspector U.S. Nuclear Regulatory Commission Catawba Nuclear Station R.E. Martin, Senior Project Manager (addressee only)

U.S. Nuclear Regulatory Commission Mail Stop 08-H12 Washington, D.C. 20555-0001

Request Relief 03.001 Page 1 of 7 Proposed Relief in Accordance with 10 CFR 50.55a (a)(3)(ii)

Inservice Inspection Hardship Duke Energy Corporation Catawba Nuclear Station - Unit 1 and 2 Second 10-Year Interval - Inservice Inspection Plan (CNS-1 began on June 29, 1995 and CNS-2 began on August 19, 1996)

ASME Section XI Code - 1989 Edition with No Addenda I.

1. & III.

IV.

V.

VI.

ViI.

I.D.

System Code Requirement from Which Relief is Basis for Relief Alternate Justification for the Implementation Schedule Number Component for Requested: 100% of the weld length Examinations or Granting of Relief Which Relief is Exam Category Testing Requested:

Item No.

Area or Weld to be Fig. No.

Examined IREGHX-SHI-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragrph "C" See Paragraph "D" HDI Exchanger Head-to-Item No. COI.020.007 (Unit 1)

Shell Weld IWC-2500-1 (a) 2REGHX-SHI-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph " C" See Paragraph "D" IIDI Exchanger Head-to-Item No. COI.020.004 (Unit 2)

Shell Weld IWC-2500-1(a)

IREGHX-SHI-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph " C" See Paragraph "D" HD2 Exchanger Head-to-Item No. COI.020.008 (Unit 1)

Shell Weld IWC-2500-1(a) 2REGHX-SHI Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" HD2 Exchanger Head-to-Item No. COI.020.005 (Unit 2)

Shell Weld IWC-2500-l(a)

I REGHX-SH2-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" HDI Exchanger Head-to-Item No. CO1.020.009 (Unit 1)

Shell Weld IWC-2500-1(a) 2REGHX-SH2-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" HDI Exchanger Head-to-Item No. CO1.020.006 (Unit 2)

I Shell Weld IWC-2500-1(a)

IREGHX-SH2-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" HD2 Exchanger Head-to-Item No. COI.020.010 (Unit 1)

Shell Weld IWC-2500-1 (a)

I

Request Relief 03.001 Page 2 of 7 I.D.

System /

Code Requirement from Which Relief is Basis for Relief Alternate Justification for the Implementation Schedule Number Component for Requested: 100% of the weld length Examinations or Granting of Relief Which Relief Is Exam Category Testing Requested:

Item No.

Area or Weld to be Fig. No.

Examined 2REGHX-SH2-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C' See Paragraph "D" HD2 Exchanger Head-to-Item No. COI.020.007 (Unit 2)

Shell Weld IWC-2500-1(a) 1 REGHX-SH3-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" HDI Exchanger Head-to-Item No. COI.020.011 (Unit I)

Shell Weld IWC-2500-l(a) 2REGHX-SH3-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" HDI Exchanger Head-to-Item No. COI.020.008 (Unit 2)

Shell Weld IWC-2500-1(a)

IREGHX-S13-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" HD2 Exchanger Head-to-Item No. COI.020.012 (Unit I)

Shell Weld IWC-2500-l (a) 2REGHX-SH3-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" HD2 Exchanger Head-to-Item No. COI.020.009 (Unit 2)

Shell Weld IWC-2500-l(a)

IREGHX-SHI-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" TS Exchanger Item No. COI.030.002 (Unit 1)

Tubesheet-to-Shell IWC-2500-2 Weld 2REGHX-SHI-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" TS Exchanger Item No. COI.030.002 (Unit 2)

Tubesheet-to-Shell IWC-2500-2 Weld I REGHX-SH2-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" TS Exchanger Item No. COI.030.003 (Unit I)

Tubesheet-to-Shell IWC-2500-2 Weld 2REGHX-SH2-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" TS Exchanger Item No. COI.030.003 (Unit 2)

Tubesheet-to-Shell IWC-2500-2 Weld IREGHX-SH3-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" TS Exchanger Item No. CO1.030.004 (Unit I)

Tubesheet-to-Shell IWC-2500-2 Weld 2REGHX-SH3-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" TS Exchanger Item No. COI.030.004 (Unit 2)

Tubesheet-to-Shell IWC-2500-2 Weld

Request Relief 03-001 Page 3 of 7 I.D.

System Code Requirement from Which Relief Is Basis for Relief Alternate Justification for the Implementation Schedule Number Component for Requested: 100% of the weld length Examinations or Granting of Relief Which Relief is Exam Category Testing Requested:

Item No.

Area or Weld to be Fig. No.

Examined IREGHX-TS-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" SI Exchanger Item No. COI.030.005 (Unit 1)

Tubesheet-to-Shell IWC-2500-2 W eld 2REGHX-TS-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" SHI Exchanger Item No. CO1.030.005 (Unit 2)

Tubesheet-to-Shell IWC-2500-2

____W eld__

I REGHX TS-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" SH2 Exchanger Item No. CO1.030.006 (Unit I)

Tubesheet-to-Shell IWC-2500-2 2REGHX TS-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" SH2 Exchanger Item No. COI.030.006 (Unit 2)

Tubeshect-to-Shell IWC-2500-2

____W eld IREGHX-TS-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" SH3 Exchanger Item No. C01.030.007 (Unit I)

Tubesheet-to-Shell IWC-2500-2 Weld 2REGHX-TS-Regenerative Heat Exam Category C-A See Paragraph "A" See Paragraph "B" See Paragraph "C" See Paragraph "D" SH3 Exchanger Item No. COI.030.007 (Unit 2)

Tubesheet-to-Shell IWC-2500-2 Weld

Request Relief 03-001 Page 4 of 7 IV. Basis for Relief Paragraph A:

Due to high radiation dose rates in the area of the Regenerative Heat Exchanger, it is station management's request that these welds not be examined. To complete the examination(s) on the Regenerative Heat Exchanger, an estimated 9,975 mrem of exposure would be received for each unit.

Listed below is a break down of the examination tasks and their respective estimates as developed by the Catawba ALARA Staff and Inservice Inspection Coordinator. The estimates assume dose rates at the time of the examination will be comparable to dose rates measured during previous outages.

The average radiation level in the vicinity of the regenerative heat exchanger is 700 mrem per hour. To achieve this dose rate, the letdown line must be isolated prior to peroxide injection (induced crud burst). Also a successful flush of the letdown line and Regenerative Heat Exchanger using water from the Reactor Make-up Water Storage Tank would be required. Both of these initiatives are routinely performed each outage.

Activity Man-Hours Average Dose Rate Activity Exposure Estimate (mrem)

Erect I Remove Scaffold 3

700 2,100 Remove / Restore Insulation 2.5 700 1,750 Weld Prep (assumes no grinding) 2.5 700 1,750 NDE 6

700 4,200 RP Support 0.25 700 175 Estimated Exposure Total 9,975 The use of temporary shielding in the area of the heat exchanger has been considered. however, preliminary evaluations using typical methods and materials suggest that the amount of exposure incurred during installation and removal would be equal to or greater than the amount of exposure saved.

In addition, structural steel supporting the heat exchangers would have to be removed to facilitate the examination process on 6 of the 12 welds or perform a limited coverage examination. The estimate shown above does not include removal and replacement of any structural steel.

Given there is no alternative volumetric or surface exam available due to similar radiation concerns, in lieu of implementing the requirements of Examination Category C-A, it is proposed that the Pressure Testing currently being performed under Examination Category C-H, "All Pressure Retaining Components" (Visual Examination, VT-2) be considered as a basis for approval of this request.

V.

Alternate Examinations or Testing Paragraph B:

None

Request Relief 03-001 Page 5 of 7 VI. Justification for the Grantint of Relief Paragraph C:

Approval of the alternative testing provided by this relief request would significantly reduce unnecessary radiological exposure to plant personnel when complying with the volumetric examination requirements, without decreasing the confidence level in the operability of the Regenerative Heat Exchanger.

The alternative testing would not result in a reduction of the level of quality and safety for the following reasons:

1. The Regenerative Heat Exchanger and associated system piping, having been designed and constructed to meet the Class 2 requirements of the 1974 edition of ASME Section III, have a low probability of failure throughout their design life. It was fabricated from austenitic stainless steel (Type 304 / 316). This material is resistant to base and weld metal degradation of the heat exchanger in the primary reactor coolant environment. The 12 welds for each unit of Catawba are not dissimilar metal welds and thus are not subjected to primary water stress corrosion cracking associated with other materials. Oxygen levels in the primary system are strictly limited, thereby greatly reducing the susceptibility to intergrannular stress corrosion cracking. Furthermore, there has been no industry operating experience that has identified these stainless materials as susceptible to significant corrosion in the primary water environment.
2.

Thermal fatigue has been considered in the design of the heat exchanger. No thermal cycling, stratification, or striping conditions have ever been identified to invalidate the qualification of the heat exchanger. While flow induced vibration of the connected letdown piping has been observed in the past, the structural integrity of the twelve shell to head and tubesheet welds is not affected.

Vibrational forces originating at the orifices are attenuated at the HX by the configuration and distance between the orifices and HX. Furthermore, past modifications have minimized the vibration levels in the letdown piping. Based on industry operating and plant specific experience, there are no known degradation mechanisms identified for these welds.

3.

Catawba Technical Specifications place conservative limits on the amount of reactor coolant leakage allowed during system operation. The reactor coolant leak detection system is in place to detect any variation in the reactor coolant inventory, including the water present in both the tube and shell side of the Regenerative Heat Exchanger, as well as its associated piping. Any weld failure would be detected by the reactor coolant leak detection system, and procedures and automatic system actions are in place to ensure that the heat exchanger would be isolated.

4.

Regenerative Heat Exchanger is isolable from the reactor coolant system by valves either operated from the control room and/or receives automatic closure signals. The shell side of the heat exchanger is isolable from the reactor coolant system by two fail closed, air operated gate valves in series.

These valves are provided a safety signal to automatically close on a Pressurizer Low-Level setpoint, which would be present with a significant leak from a Regenerative HX Shell-to-Head or Shell-to-Tubesheet weld failure. The tube side is isolable from the high pressure charging system by two motor operated gate valves in series, which are controlled from the Control Room and/or automatically close on a Safety Injection Signal (SS), which would be present with a significant HX weld leak. Regenerative Heat Exchanger is located inside the Containment Building, which is designed to contain any leakage.

5.

Visual examinations associated with Pressure Testing of the Regenerative Heat Exchangers during the latest refueling outages for Unit 1 (EOC12) and Unit 2 (EOC1 1) did not identify any evidence of weld leakage.

Request Relief 03-001 Page 6 of 7 VII. Implementation Schedule Paragraph D:

During the second 10-year inspection interval, the Regenerative Heat Exchanger Pressure Testing examinations are scheduled and will be performed in accordance with the requirements of Table IWC-2500-1, Examination Category C-H, "All Pressure Retaining Components". The Pressure Testing examination schedules are shown below.

Catawba Unit 1 Test Zone Inspection Date End of Cycle Period Leak Test INV-OOIL-B 01/03/98 10 1 Period Leak Test INV-OOIL-B 11/19/00 12 2Id Period Hydro Test INV-OOIH-B To Be Done 14 and 15 3d Period Catawba Unit 2 Test Zone Inspection Date End of Cycle Period Leak Test 2NV-OOIL-B 10/18/98 9

1" Period Leak Test 2NV-OOIL-B 10/20/01 11 2nd Period Hydro Test 2NV-OO1H-B To Be Done 13 and 14 3" Period VIII. Other Information Catawba Unit 1 Examination Category C-A There are twenty-six (26) welds that make up the total population for this examination category, all of which are scheduled for examination during the current 10-year inspection interval. With the elimination of twelve (12) Regenerative Heat Exchanger weld examinations sought by this relief request, the Table IWC-2412-1 code requirement to complete 100% of the total number of examinations within a category by the end of an interval will not be met.

Excluding the twelve (12) Regenerative Heat Exchanger welds, the remaining fourteen (14) weld examinations will be performed in this category. Based on the original category total population, the end of interval completion percentage will be (26-12) / 26 =14 / 26 = 53.85%, not 100 % as required in Table IWC-2412-1.

Relief is requested from the above requirements of Paragraph IWC-2412 and Table IWC-2412-1.

Catawba Unit 2 Examination Category C-A There are twenty-nine (29) welds that make up the total population for this examination category, all of which are scheduled for examination during the current 10-year inspection interval. With the elimination of twelve (12) Regenerative Heat Exchanger weld examinations sought by this relief request, the Table IWC-2412-1 code requirement to complete 100% of the total number of examinations within a category by the end of an interval will not be met.

Excluding the twelve (12) Regenerative Heat Exchanger welds, the remaining seventeen (17) weld

Request Relief 03-001 Page 7 of 7 examinations will be performed in this category. Based on the original category total population, the end of interval completion percentage will be (29-12) /29 =17 /29 = 58.62%, not 100 % as required in Table IWC-2412-1.

Relief is requested from the above requirements of Paragraph IWC-2412 and Table IWC-2412-1.

The following individuals contributed to the development of this relief request.

Roy Riddle (ALARA Specialist, Catawba) developed dose estimates for Regenerative Heat Exchanger.

Hugh Mason and Bill Callaway (Plant Engineering, Catawba) contributed justification for granting of relief.

Andy Hogge and Jimmy Cherry (Inservice Inspection Plan Management, GO) developed the relief request and addressed code requirements.

Attachments:

1.

Sub-Assembly and Details Drawing of Regenerative Heat Exchanger (Catawba Unit 1)

2.

Sub-Assembly and Details Drawing of Regenerative Heat Exchanger (Catawba Unit 2)

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